Sulzer Metco (US) Inc.

Oerlikon Metco (US) Inc.

The Perkin-Elmer Corporation

Sulzer Metco Inc.

Oerlikon Metco Inc.

Mitchell R Dorfman

Liangde Xie

Richard Karl Schmid

Matthew Gold

Burton A Kushner

Jacobus Cornelis Doesburg

Jacobus C Doesburg

Michael Mueller

Luis F Correa

Christopher G Dambra

Komal Laul

Franz Jansen

Dianying Chen

Ronald Eugene Somoskey, Jr

Kerry LaPierre

Lysa Russo

Xiaohan Wei

Ashish Patel

John Peters

Anthony J Rotolico

Massimo Giannozzi

Iacopo Giovannetti

Subramaniam Rangaswamy

John H Harrington

Petr Fiala

Scott Wilson

Omar Basil Al-Sabouni

Montia Nestler

Roger W Kaufold

Edward R Novinski

Jorge E Garcia

Joseph D Reardon

Chris Dambra

Andrew R Nicoll

Dieter R Sporer

Ulrike Taeck

Josph D Reardon

Walter Pietrowicz

Daniel Garcia

Farshad Ghasripoor

Eric Kozculab

Dieter Rudolf Sporer

Roopnarine Tilkaran

Eric J Reents

Gustavo Arevalo

Ronald E Somoskey

Eric Reents

Omar B Al-Sabouni

Montia C Nestler

Brian A Delre

An erosion and CMAS resistant coating arranged on a TBC coated substrate and including at least one porous vertically cracked (PVC) coating layer providing lower thermal conductivity and being disposed over a layer of MCrAlY wherein M represents Ni, Co or their combinations. At least one dense vertically cracked (DVC) erosion and CMAS resistant coating layer is deposited over the at least one PVC coating layer.

CMAS resistant, high strain tolerant and low thermal conductivity thermal barrier coatings and thermal spray coating method

Articles coated with a porous, segmented thermal barrier coating. The coating described has a density less than about 88% of the theoretical density. Multi-layer articles and methods of applying the thermal barrier coatings to an article are also described.

Thermal barrier coatings and processes

A high purity yttria or ytterbia stabilized zirconia powder wherein a purity of the zirconia is at least 99.5 weight percent purity and with a maximum amount of specified oxide impurities.

Ceramic material for high temperature service

Thermal barrier coating made from a thermally sprayable powder that includes yttria stabilized zirconia and hafnia, from 6 to 9 weight percent yttria, and total impurities less than or equal to about 0.1 weight percent. The thermal barrier coating has from about 5 to 250 vertical macro cracks per 25.4 mm length measured along a coating surface and the macro cracks are oriented perpendicular to a surface of a substrate containing said coating.

A thermal spray powder having a first component A mechanically blended with a second component B, wherein the first component A is a metal or metal composite, preferably at least one of Ni&#x2014;Cr&#x2014;Al clad ABN, Ni&#x2014;Cr&#x2014;Al clad HBN, Ni&#x2014;Cr&#x2014;Al clad agglomerated hexagonal boron nitride powder with organic binder, Ni&#x2014;Cr&#x2014;Al agglomerated hexagonal boron nitride powder with inorganic binder, an MCrAlY type powder where M is at least one of Ni, Co, Fe, and wherein component B is a polymer clad with at least one of nickel, nickel alloys, nickel chrome alloys, nickel chrome aluminum alloys, nickel aluminum alloys, cobalt and cobalt alloys. The result is a thermal spray powder of four distinctly different phases making the powder a four-phase blend.

Abradable composition and method of manufacture

The present invention provides a high-purity fused and crushed stabilized zirconia powder. The powder&#x2014;with or without further processing, such as plasma spheroidization&#x2014;is used in thermal spray applications of thermal barrier coatings (TBCs) and high-temperature abradables. The resulting coatings have a significantly improved high temperature sintering resistance, which will enhance the durability and thermal insulation effect of the coating.

High-purity fused and crushed zirconia alloy powder and method of producing same

A metal oxide powder includes a powder feed material structured and arranged to form molten droplets when melted in a plasma stream. The molten droplets are structured and arranged to form frozen spherical droplets under free-fall conditions such that said molten droplets have ample time for complete in-flight solidification before reaching a collection chamber.

High purity and free flowing metal oxides powder

The invention is directed to a material and method for obtaining a ceramic abradable system for high temperature applications. High purity partially stabilized zirconia and/or hafnia base material has higher sintering resistance compared to conventional 6-9 weight percent yttria stabilized zirconia systems. The benefits of these systems are higher service lifetime and low thermal conductivity to achieve high operating temperatures. System includes a superalloy substrate, oxidation resistant bond coat and a thick ceramic abradable top coat. Total coating thickness is about 0.5-5 mm. In some applications an intermediate layer of high purity partially stabilized zirconia or a partially stabilized YSZ/MCrAlY cermet is applied over the oxidation resistant bond coat. In other applications an abradable system is applied on top of a grid. Additional benefits should be reduced blade wear at high operating conditions.

High purity ceramic abradable coatings

Ceramic abradable materials, in particular thermally sprayable ceramic abradable powder materials, and abradable seals formed by thermally spraying the materials include dysprosia (DyO) and zirconia (ZrO). Coatings are porous whereby the porosity, in part, is induced by plastic or fugitive phases. Abradable seal coatings comprising dysprosia and zirconia exhibit improved thermal shock and sintering resistance and can be worn into tolerance by untreated, bare turbine blades, at least in certain regimes of relative blade speed and coating porosity. Ceramic abradable seal coatings comprising dysprosia and zirconia can be used up to 1200&#xb0; C.

Dysprosia stabilized zirconia abradable

According to aspects of the present invention, metal oxide powder, such as yttria and alumina powder (feed material), is processed using a plasma apparatus. The process generally consists of in-flight heating and melting of the feed material by the plasma apparatus. The plasma apparatus contains a plasma torch with required power supply and cooling systems, a powder feeder, a chamber to collect the powder and a dedusting system. The heated powder forms molten spherical droplets that are rapidly cooled under free fall conditions. The plasma densification process removes some impurity oxides, modifies the morphology of the particle and increases the apparent density of the powder.

Method for making high purity and free flowing metal oxides powder

The present invention provides a low density and porous zirconia (ZrO) powder partially alloyed with one or more of yttria, scandia, dysprosia, ytterbia, or any of the oxides of lanthanide or actinide. The total amount of alloying oxides should be less than about 30 weight percent. The powder is manufactured by controlled sintering or light plasma densification of physically agglomerated, or chemically derived zirconia composite powder that contains proper amounts of yttria, scandia, dysprosia, ytterbia, or any of the oxides of lanthanide or actinide, or any combination of the aforementioned oxides. The resulting coating from use of the inventive powder has a monoclinic phase content of less than 5 percent.

Partially-alloyed zirconia powder

The invention is directed to a ceramic material for use in thermal barriers for high temperature cycling applications and high temperature abradable coatings. The material is an alloy formed predominantly from ultra-pure zirconia (ZrO) and/or hafnia (HfO) that has uncharacteristically high sintering resistance to achieve a high service lifetime and low thermal conductivity to achieve high operating temperatures. In the material, oxide impurities such as soda (NaO), silica (SiO), alumina (AlO), titania (TiO), hematite (FeO), calcia (CaO), and magnesia (MgO) make up no more than 0.15 weight percent. The invention provides materials to produce a coating structure so that the changes in the coating microstructure over the in-service lifetime are either limited or beneficial.

A pre-alloyed stabilized zirconia powder suitable for use in thermal barrier applications is formed by alloying zirconia with a stabilizer, such as yttria, and processing the alloyed stabilized zirconia to form a very fine powder. The raw powder is then spray-dried to produce an agglomerated powder having an average particle size suitable for use in spray coating applications. The resulting powder can be used in a thermal-spray application to produce a porous thermal barrier coating having a substantially decreased thermal conductivity when compared to conventional TB coatings, such those produced using plasma-densified powders.

Method of producing a pre-alloyed stabilized zirconia powder

A powder of dicalcium silicate is made by spray drying calcia and silica with incorporation of sodium and phosphorus or stabilized zirconia. The spray dried powder is sintered to form a thermal spray powder. Sprayed coatings have a web of interconnected, randomly oriented microcracks substantially perpendicular to the coating surface. The coatings are stable in thermal cycling and a hot corrosive environment.

Thermal spray powder of dicalcium silicate and coating thereof and manufacture thereof

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Smithtown, NY, United States of America

Mitchell R Dorfman